Gap Filling System

ABSTRACT

A concrete construction ( 10 ) comprises a first slab ( 11 ) and a second slab ( 12 ), there being a gap ( 13 ) between the slabs. The gap ( 13 ) may be formed by removing form work or it may be an expansion joint or a crack induction joint which requires a surface finish. An expandable gap filler support member in the form of a spacer ( 14 ) is inserted into the gap before application of a caulking compound as filler. The spacer ( 14 ) is an extruded strip which has two opposing Y shaped sections ( 15 ) and ( 16 ) set back-to-back and formed as a symmetrical unit having divergent flanges ( 17 ), ( 18 ), ( 19 ) and ( 20 ) which are able to flex so that the spacer ( 14 ) may be inserted in the gap ( 13 ). As the slabs ( 11 ) and ( 12 ) expand and contract the arms ( 17 ), ( 18 ), ( 19 ) and ( 20 ) will flex with that movement. In the case of gaps of greater depth multiple spacers may inserted one atop the other.

FIELD OF THE INVENTION

THIS INVENTION relates to a gap filling system employing an expandablespacer and in particular but not limited to an expandable spacer adaptedto receive and support a past-like filler in predetermined quantity asused in various constructions including floors, walls and the like.

BACKGROUND OF THE INVENTION

Historically, problems concerned with maintaining the integrity ofconcrete slabs is not a new thing, it being usual to provide some formof controlled cracking to induce subsurface cracking by a surface sawcutor crack inducer pushed into the surface.

Slabs are often equipped with various joints including contraction andexpansion joints and some of these can leave a gap in the concretesurface as well.

In the case of a saw cut used to induce cracking, it is usual to fillthe gap with some form of filler. Typically, this could be an extrudedinsert strip, paste filler or caulking compound applied to the gap or acombination of the two. An adhesive may be applied. Also it is usual tomake provision in the gap filler for expansion and contraction.

Apart from concrete, gap fillers are widely used in all fields and thepresent invention while having application to gap filling in concretehas general application. The following are examples of what is typicalin the prior art, it being appreciated that the art is a well developedone and a prior art search shows all manner of devices used to fillgaps. Gaps occur in other situations where fillers are used, includingtensioning fillers for fly screens in window frames for holding thescreens, seals in doors and windows and so on.

The following prior art documents were located in the PCT Article 15/5search and the inclusion herein should not be considered as anyadmission that any of these documents are common general knowledge inthe art. The applicant considers these are merely exemplary of the widevariety of the prior art to the extent that the present invention, beinga simple one, should not be viewed as obvious, but rather as inventivein a highly developed art it being more difficult to invent in an artthat is so highly developed.

U.S. Pat. No. 6,336,300 (BABUCK) describes a gap filler system for usein a timber deck to fill and seal gaps between planks in the deck. Thefiller is a strip made from an elongate block of rubber shaped to suitthe shape of the gap between the planks depending on whether the plankshave rounded or square edges. The strip relies on its blockiness and istight fitting being slightly wider than the gap and physically fills thegap in a compressed into the gap state. Further it has an enlargedbifurcated upper edge with flanges which form a channel for runoff. Theflanges are biassed out on to the tops of the planks to form a seal. Anadhesive may be applied between the flanges and the planks. In anotherembodiment the opposite edge of the strip is enlarged and projects outon the opposite side of the deck so the strip extends through the deck.

U.S. Pat. No. 4,141,189 (BORJESON) describes a gap filler in the form ofa seal forced into a joint and able to expand and contract by reason ofcompression applied at the time of insertion. The seal is an extrudedsection having opposed V-shaped arms extending on opposite sides of aweakened region forming an elongate hinge so that opposite edges of thearms may be forced together against the bias afforded by the V-shapedsection of the arms. A flat insertion tool in the form of a rolling discis placed between the arms at the time of insertion and the strip isforced into the gap with a rolling action of the disc. When the tool isremoved the V-shaped section of the arms compressed against the wall ofthe gap, forces the upper edges of the arms together. The upper edges ofthe arms have interlocking grooves so they are keyed together. The armsmay include outwardly projecting fingers or ribs to enhance sealing. Asthe joint expands and contracts the arms flex back and forth about thehinge. There is no caulking compound used with this strip.

WO 2003/048470 (REDDIPLEX GROUP PLC) describes an I-shaped sealing striphaving curved ends and a narrow web between the ends. The ends widerthan the gap being filled so they deform upon insertion. The strip isinserted into the gap and is stabilised and held straight by reason ofits I-shape. The web is made from an expandible material that expands incase of fire.

U.S. Pat. No. 4,290,249 (MASS) describes a sealing strip which operatessimilar to the BORJESON seal in so far as it is V-shaped, has two armsand a hinge between them. The arms are biassed apart by a V-shapedspring steel insert encapsulated in the strip.

As set out above there are many and varied arrangements for fillinggaps, and the present invention comes into a field as a simple anduseful alternative, it being non-obvious on the basis of it being moredifficult to invent in a highly developed field where it was thoughtthat “everything has been invented.” accordingly the present inventionhas as its primary object to at least provide the public with a usefulalternative in a highly developed field. A further object is to providea simple inexpensive extruded gap filler and caulking compound supportas an alternative to the prior art.

OUTLINE OF THE INVENTION

In one aspect there is provided a filled gap in a concrete construction,including a space filling aid comprising an elongate body adapted forresilient insertion into a gap, the gap being of the type havingconfronting side walls separated by a space, the elongate body having anelongate paste receiving cavity of predetermined volume which bridgesacross the body to hold filler paste applied into the cavity, theelongate body being adapted to expand and retract as the space betweenthe walls changes and a filler paste layed while flowable and allowed toharden being held in the cavity.

In another aspect there is provided a space filling aid comprising anelongate body adapted for resilient insertion into a gap, the gap beingof the type having confronting side walls separated by a space, theelongate body having an elongate paste receiving cavity of predeterminedvolume which bridges across the body to hold filler paste applied intothe cavity, the elongate body being adapted to expand and retract as thespace between the walls changes, the body comprising a thin walledextruded member having an upper bifurcated longitudinally extendingsection joined at a juncture between the arms, with the opposed armsbeing adapted to flex inwardly about the juncture.

Preferably, the juncture between the arms comprises a transverse sectionextending between the arms and leading to a web extending away from thearms.

Preferably, the juncture between the arms comprises a transverse sectionextending between the arms and leading to a web extending away from thearms, the transverse section being sufficiently rigid to provide springbias to the arms.

Preferably, the juncture between the arms comprises a transverse sectionextending between the arms and leading to a web extending away from thearms, the web extending to a further juncture and a further set of armsopposite the first set of arms.

Preferably, the body comprises a pair of spaced longitudinal extendingarm members adapted to flex inwardly upon insertion into the gap and tospring back against the walls.

Preferably, the body is generally cruciform in cross section.

Preferably, the body is generally dumbbell shaped in cross-sectionhaving back-to back-pairs of arms in the form of divergentlongitudinally extending pairs of resilient flange members.

Preferably, the body is generally symmetrical in transverse crosssection.

Preferably, the body is generally dumbbell shaped in cross-sectionhaving back-to back-pairs of arms in the form of divergentlongitudinally extending pairs of resilient flange members and eachflange having a turned over peripheral marginal edge portion.

Preferably, the body is generally dumbbell shaped in cross-sectionhaving back-to-back-pairs of arms in the form of divergentlongitudinally extending pairs of resilient flange members having aspace between adjacent arms, the space between adjacent arms definingthe cavity as a paste receiving channel which is V-shaped in profile andthe paste being held in the channel as a strip.

In another aspect there is provided a method of gap filling whereby anelongate gap filler support member is initially positioned in a gapproviding a seat for a filler paste layed while flowable and allowed toharden, the support member having an open channel of predeterminedvolume whereby gap filler may be located in the channel to finishfilling the gap and be supported by the support member, the methodcomprising inserting the support member into a gap so that the openchannel is just below the surface adjacent to the gap and subsequentlyapplying the paste to the channel to complete filling of the gap.

Preferably, the support member has two opposite edges adapted to be selfholding in the gap, the method including pushing the first edge into thegap followed by the second edge, the second edge having said openchannel.

Preferably, the support member is itself supported by an auxiliarysupport member located underneath, the method including pushing theauxiliary support member into the gap first. Preferably, the methodincludes pushing the auxiliary support member into the gap first and thesupport member and auxiliary support member are functionally equivalentand interchangeable.

In practicing the method the preferred support member comprises a spacefilling aid according to the second aspect.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention may be more readily understood andbe put into practical effect reference will now be made to theaccompanying drawings which illustrate various preferred embodiments andwherein:—

FIGS. 1A and 1B illustrate the process whereby an expandable spaceraccording to the present invention is inserted into a gap;

FIG. 2 illustrates application of a spacer to an expansion joint in theconcrete slab where a dowel is employed;

FIG. 3 illustrates the application of the invention to a slab wherethere is no dowel;

FIG. 4 illustrates application of spacers in a back to back arrangement;

FIG. 5 illustrates application of the invention in a wall panel;

FIG. 6 is similar to the embodiment of FIG. 5 but employing spacers inback-to-back relationship;

FIGS. 7A and 7B illustrate in greater detail the spacer of FIGS. 2, 4and 6; and

FIGS. 8A and 8B illustrate in greater detail the other spacer of thetype illustrated in FIGS. 1A, 1B, 3 and 5.

METHOD OF PERFORMANCE

Referring to the drawings and initially to FIGS. 1A and 1B there isillustrated a concrete construction 10 comprising a first slab 11 and asecond slab 12, there being and a gap 13 between the slabs. The gap 13may be formed by removing form work or it may be an expansion joint or acrack induction joint which requires a surface finish. This is oftenprovided by putting paste filler into the gap. In order to control theamount of gap filler delivered into the gap 13 the present invention isutilised whereby expandable gap filler support member in the form of aspacer 14 inserted into the gap before application of filler.

In this case the spacer 14 is an extruded strip which has two opposing Yshaped sections 15 and 16 set back-to-back and formed as a symmetricalunit having divergent arms in the form of flanges 17, 18, 19 and 20which are able to flex as shown in FIG. 2 so that the spacer 14 may beinserted in the gap 13. As the slabs 11 and 12 expand and contract thearms 17, 18, 19 and 20 will flex with that movement.

As can be seen a V-shaped channel 21 is formed between the flanges 17and 18 in the spacer and this channel may be utilised to receive andhold a filler paste to complete and fill the gap. It will be appreciatedthat the amount of filler required will be limited by the volume of thechannel 21 and that portion of the gap located above the channel. Thisis more easily seen in FIG. 2. It will also be appreciated that thesymmetrical construction of the spacer provides an opposing channel sothat the spacer is reversible for ease of use and for applications towalls as described below but it will be appreciated that it need not besymmetrical. In fact there are clearly a large number of possiblecross-sections that will work.

In FIG. 2 a spacer 22 is seated upon a dowel 23 projecting into adjacentslabs 24 and 25. The spacer 22 comprises back-to-back V sections and theupper V section is shown filled with a suitable filler 26 to completethe filling of the gap. It will be appreciated that the expandablespacer 22 is able to flex with relative movement of the slabs along thedowel 23 and also in response to any downward pressure upon the filler26, the arms will flex slightly but this will be tempered due to theturned marginal edges 27 and 28 engaging the walls 29 and 30. It will befurther appreciated that the volume of filler 26 will be economised byutilising the spacer 22.

The flexing of the arms is afforded by the transverse juncture 31between the arms.

FIGS. 3, 4, 5, 6 illustrate further embodiments of the invention andfurther applications the two types of spacers depicted in FIGS. 1A and2; and

FIGS. 7A through 8B illustrate typical examples of typical spacersshowing the compressed position of the flanges of the spacer in phantomin FIGS. 7B and 8B.

It will be appreciated that although the spacer is illustrated in theshapes and configurations of FIGS. 7A through 8B that any form ofexpandable spacer that may be located and secured in position in orderto receive a defined volume of filler to economise the amount of filleremployed and function equivalent to the embodiments illustrated may beutilised in practice of the method of the present invention in terms ofits gap filling function. The invention may be used in any suitablesituation, FIGS. 5 and 6 being in respect of wall panelling while theother drawings are in respect of concrete.

Whilst the above has been given by way of illustrative example of thepresent invention many variations and modifications thereto will beapparent to those skilled in the art without departing from the broadambit and scope of the invention as set out in the appended claims. Forexample, where “comprising” is used it is not intended to be exclusivebut the features listed are the minimum and additional features added tothe combination is still within the scope of the invention described andclaimed. Also where the description refers to a pair of arms the armsneed not be identical arms and pair does not exclude additional arms inaddition to the pair.

1. A filled gap in a concrete construction, including a space fillingaid comprising an elongate body adapted for resilient insertion into agap, the gap being of the type having confronting side walls separatedby a space, the elongate body having an elongate paste receiving cavityof predetermined volume which bridges across the body to hold fillerpaste applied into the cavity, the elongate body being adapted to expandand retract as the space between the walls changes and a filler pastelayed while flowable and allowed to harden being held in the cavity. 2.A filled gap in a concrete construction according to claim 1 wherein thebody comprises a pair of spaced longitudinal extending arm membersadapted to flex inwardly upon insertion into the gap and to spring backagainst the walls.
 3. A filled gap in a construction according to claim1 wherein the body is generally cruciform in cross section.
 4. A filledgap in a construction according to claim 1 wherein the body is generallydumbbell shaped in cross-section having back-to back-pairs of arms inthe form of divergent longitudinally extending pairs of resilient flangemembers.
 5. A filled gap in a construction according to claim 1 whereinthe body is generally be symmetrical in transverse cross section.
 6. Afilled gap in a construction according to claim 1 wherein the body isgenerally dumbbell shaped in cross-section having back-to back-pairs ofarms in the form of divergent longitudinally extending pairs ofresilient flange members and each flange has a turned over peripheralmarginal edge portion.
 7. A filled gap in a construction according toclaim 1 wherein the body is generally dumbbell shaped in cross-sectionhaving back-to-back-pairs of arms in the form of divergentlongitudinally extending pairs of resilient flange members having aspace between adjacent arms, the space between adjacent arms definingthe cavity as a paste receiving channel which is V-shaped in profile andthe paste being held in the channel as a strip.
 8. A method of gapfilling whereby an elongate gap filler support member is initiallypositioned in a gap providing a seat for a filler paste layed whileflowable and allowed to harden, the support member having an openchannel of predetermined volume whereby gap filler may be located in thechannel to finish filling the gap and be supported by the supportmember, the method comprising inserting the support member into a gap sothat the open channel is just below the surface adjacent to the gap andsubsequently applying the paste to the channel to complete filling ofthe gap.
 9. The method according to claim 8 where the support member hastwo opposite edges adapted to be self holding in the gap, the methodincluding pushing the first edge into the gap followed by the secondedge, the second edge having said open channel.
 10. The method accordingto claim 8 where the support member is itself supported by an auxiliarysupport member located underneath, the method including pushing theauxiliary support member into the gap first.
 11. The method according toclaim 8 where the support member is itself supported by an auxiliarysupport member located underneath, the method including pushing theauxiliary support member into the gap first and the support member andauxiliary support member are functionally equivalent andinterchangeable.
 12. A space filling aid comprising an elongate bodyadapted for resilient insertion into a gap, the gap being of the typehaving confronting side walls separated by a space, the elongate bodyhaving an elongate paste receiving cavity of predetermined volume whichbridges across the body to hold filler paste applied into the cavity,the elongate body being adapted to expand and retract as the spacebetween the walls changes, the body comprising a thin walled extrudedmember having an upper bifurcated longitudinally extending sectionjoined at a juncture between the arms, with the opposed arms beingadapted to flex inwardly about the juncture.
 13. A space filling aidaccording to claim 12 wherein the arm members are adapted to flexinwardly upon insertion into the gap and to spring back against thewalls.
 14. A space filling aid according to claim 12 wherein the body isgenerally cruciform in cross section.
 15. A space filling aid accordingto claim 12 wherein the body is generally dumbbell shaped incross-section having back-to back-pairs of arms in the form of divergentlongitudinally extending pairs of resilient flange members.
 16. A spacefilling aid according to claim 12 wherein the body is generally besymmetrical in transverse cross section.
 17. A space filling aidaccording to claim 12 wherein the body is generally dumbbell shaped incross-section having back-to back-pairs of arms in the form of divergentlongitudinally extending pairs of resilient flange members and eachflange has a turned over peripheral marginal edge portion.
 18. A spacefilling aid according to claim 12 wherein the body is generally dumbbellshaped in cross-section having back-to-back-pairs of arms in the form ofdivergent longitudinally extending pairs of resilient flange membershaving a space between adjacent arms, the space between adjacent armsdefining the cavity as a paste receiving channel which is V-shaped inprofile.
 19. A space filling aid according to claim 12 wherein thejuncture between the arms comprises a transverse section extendingbetween the arms and leading to a web extending away from the arms. 20.A space filling aid according to claim 12 wherein the juncture betweenthe arms comprises a transverse section extending between the arms andleading to a web extending away from the arms, the transverse sectionbeing sufficiently rigid to provide spring bias to the arms.
 21. A spacefilling aid according to claim 12 wherein the juncture between the armscomprises a transverse section extending between the arms and leading toa web extending away from the arms, the web extending to a furtherjuncture and a further set of arms opposite the first set of arms.